Comprag RDX Series User manual

OPERATING MANUAL
BEDIENUNGSANLEITUNG
Version 1.4
Version 1.4
compressed air refrigerating dryer
Druckluft Kältetrockner
RDX series
RDX-Serie
EN
DE
RU
РУКОВОДСТВО ПО ЭКСПЛУАТАЦИИ
Версия 1.4
Осушитель сжатого воздуха
рефрижераторного типа
серии RDX
Seite. 25
стр. 47
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3
COMPRAG RDX series compressed air refrigerated dryer
Contents
1 Safety guidelines 4
1.1 Symbols used in the instructions 4
1.2 General safety guidelines 4
1.3 Safety precautions for start-up 5
1.4 Safety precautions during operation 6
1.5 Safety precautions for maintenance and repair 7
2 Technical data and functional description 9
2.1 Technical data 9
2.2 Function 10
2.3 Functional description 11
2.4 Conversion table of performance for different operating conditions 12
3 Start-up 12
3.1 Acceptance of dryer 12
3.2 Dimensions of dryer 13
3.3 Preparation of facility 14
3.4 Preparation of compressed-air line 14
3.5 Electrical connection 14
4 Usage 16
4.1 Control panel 16
4.2 Before use and on a weekly basis 20
4.3 Turning on dryer 20
4.4 Turning off dryer 20
5 Adjusting and maintenance 21
5.1 Hot gas bypass valve adjustment 21
5.2 Condensate drain valve adjustment 22
5.3 Cleaning condenser 22
6 Fault handling 23
7 Storage 24
EN
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4Version 1.4
1. Safety guidelines
1.1 Symbols used in the instructions
Lethal hazard
Warning
Attention
1.2 General safety guidelines
Carefully familiarise yourself with the technical documentation,
operating instructions and safety guidelines. Most accidents as-
sociated with the use of compressor equipment occur as a result
of non-compliance with safety guidelines. Prevent hazards from
developing and adhere to the safety guidelines. The main rules
are given in the following section.
The user is solely liable for injuries or damages which occur due to
non-compliance with safety guidelines during installation, opera-
tion or servicing, as well as unauthorised use of equipment!
1 The operator must stringently adhere to safety guidelines provided for by these instruc-
tions and local legislation!
2. When choosing between these safety guidelines and the regulations provided for by
local legislation, those rules which provide for more stringent requirements shall apply.
3. Only trained maintenance personnel with the relevant level of professional training are
permitted to operate, service and repair Comprag equipment.
4. Compressed air owing immediately from the compressor may contain oil and impurities
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COMPRAG RDX series compressed air refrigerated dryer
and is not suitable for breathing! Compressed air has to be puried to an air purity grade
suitable for breathing, in accordance with the standards prescribed by local legislation.
5. Compressed air is an extremely hazardous energy source. Compressed air must not
be used for unintended purposes! Do not use it to clean clothing and footwear and never
point compressed air hoses at people and animals! When using air to clean equipment,
take extra caution and wear safety goggles!
6. All maintenance, repair, setup and installation work etc. must be performed while the
equipment is turned off, disconnected from the power source, with compressed-air hoses
disconnected from the equipment, and with the use of safety goggles! Ensure that equip-
ment is disconnected from the compressed air system and is not under pressure.
1.3 Safety precautions for start-up
The user is solely liable for injuries or damages which occur due to
non-compliance with safety guidelines during installation, opera-
tion or servicing, as well as unauthorised use of equipment!
1. Equipment must only be unloaded/loaded using the appropriate handling devices or
hoisters. Equipment must not be manually lifted or moved. Do not leave equipment sus-
pended. Use a helmet during unloading operations.
2. Arrange the equipment in a dry and clean facility which provides shelter from precipi-
tation. The facility must be well ventilated, and forced ventilation should be provided if
necessary.
3. Worn, damaged or spoiled compressed-air hoses should not be used. Ensure that
hoses correspond to the equipment in terms of nominal diameter and working pressure.
4. When using several compressor stations in a system, each compressor must have a manu-
ally operated valve for cutting off any of the compressors in the case of emergency.
5. Explosive and re-hazardous admixtures such as solvent vapours and carbon dust etc.
must not be released into the atmosphere.
6. Ensure unrestricted access to the compressed-air hose from the compressor. Do not
clutter it and do not store ammable materials in its immediate vicinity.
7. Do not pinch or deform the compressed-air feed hoses.
8. Do not cover holes used to provide equipment with air for cooling. Ensure the facility is well
ventilated.
9. When using remote control, the equipment must give a legible and clear warning of this:
‘ATTENTION: this machine is being controlled remotely and may start operating without
warning!’ An operator who is remotely controlling equipment must ensure that no installa-
tion or other work is being performed with the equipment at that moment. Once the equip-
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6Version 1.4
ment is turned off remotely, the operator must ensure that the equipment is actually turned off!
10. Equipment must be earthed. Provide short-circuit protection. The starting knife switch
must be in the immediate vicinity of the equipment and protect against unauthorised start-up.
The user bears full responsibility for compliance with the operating condi-
tions of the electrical motor installed in the equipment.
Equipment must be used with protection devices.
The protection devices must protect the electric motor from short circuits,
overloading (systematic and start-up) and open-phase conditions.
Installation of protection devices is the responsibility of the user.
11. There must be an information plate afxed next to the control panel on equipment with
an independent control system featuring an automatic restart function: ‘ATTENTION: This
machine may start operating without warning!’
12. Any tanks and vessels working under pressure must be tted with safety-relief valves!
Unauthorised installation, disassembly or adjustment of attached safety-relief valves is
not allowed.
1.4 Safety precautions during operation
The user is solely liable for injuries or damages which occur due to
non-compliance with safety guidelines during installation, opera-
tion or servicing, as well as unauthorised use of equipment!
1. Ensure that hoses correspond to the equipment in terms of nominal diameter and working
pressure. Check the attachment of every hose coupling before start-up. An insecurely fas-
tened hose may cause serious injury.
2. Never turn on equipment if you suspect the presence of highly ammable impurities in the air!
3. The operator remotely controlling equipment must ensure that no installation or other work
is being performed with the equipment at that moment! An information plate must be afxed
to the equipment in relation to this: ‘ATTENTION: this machine is being controlled remotely
and may start operating without warning!’
4. An operator is not allowed to operate equipment if the operator is fatigued, in a state of
intoxication from alcohol, drugs or medicine that reduces the body’s reaction time.
5. The equipment must not be operated if parts of the casing have been removed. Doors or
panels may be opened for short durations for inspection and scheduled checks. It is advis-
able to wear hearing protection.
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COMPRAG RDX series compressed air refrigerated dryer
In some types of equipment, open doors or removal of panels du-
ring operation may lead to overheating.
6. Personnel in conditions or a facility where the sound pressure level reaches or exceeds
90 dB (A), must wear ear protectors.
7. If the air used for cooling equipment is used while the facility is being heated, undertake
measures for it to be ltered so that it is suitable for breathing.
8. Regularly check that:
• safety devices and attachments are in place;
• all hoses and pipes are in good condition and sealed;
• there are no leaks;
• brackets and structural components are tightened;
• all electrical cables and contacts are in good condition and safe to use;
• safety devices are fully functional and there is no contamination etc;
• all structural components are in working order, with no signs of wear and tear.
1.5 Safety precautions for maintenance and repair
The user is solely liable for injuries or damages which occur due to
non-compliance with safety guidelines during installation, operati-
on or servicing, as well as unauthorised use of equipment!
1. Only original spare parts and ancillary items may be used. Using spare parts from other
manufactures may lead to unpredictable results and consequently accidents.
2. When performing installation and repair work, always wear goggles!
3. Before connecting or disconnecting equipment, disconnect it from the main pneumatic
system. Ensure that the hoses aren’t under pressure!
4. Before beginning installation or other work, ensure that equipment is not pressurised.
Installation work must not be carried out on equipment under pressure.
5. All maintenance work should be carried out only when the temperature of all structural
elements falls to room temperature.
6. Never use highly ammable solvents or carbon tetrachloride for cleaning structural ele-
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8Version 1.4
ments. When wiping, take precautions against the poisonous vapours of cleaning uids.
7. When carrying out installation and repair work, an information plate should be afxed
to the control panel to warn against unauthorised start-up. For example, “Do not turn on.
Personnel operating!”
8. The operator remotely controlling equipment must ensure that no installation or other
work is being performed with the equipment at that moment! An information plate must be
afxed to the equipment in relation to this: See 1.3.9.
9. Maintain cleanliness in the facility where the equipment is installed. Close open inlets
and outlets during installation with dry clothes or paper to prevent rubbish entering the
equipment.
10. Welding or other similar operations must not be carried out in the immediate vicinity of
the equipment and vessels under pressure.
11. If there is any suspicion of overheating, combustion or other emergency, turn off the
equipment. Immediately disconnect it from the power supply. Do not open the doors of
equipment until the temperature falls to room temperature, in order to prevent burns or injury.
12. Naked ames must not be used as a light source for inspecting and checking equipment.
13. Never use caustic solvents, which may damage materials of the pneumatic system
14. After performing installation or other work, ensure that no instruments, rags or spare
parts have been left inside the equipment.
15. Pay particular attention to the safety-relief valves. Thoroughly inspect them and remove
any dust and dirt. They must not be allowed to suffer any loss in function under any circum-
stances. Remember that your safety depends on their functionality!
16. Before beginning work in normal mode after maintenance or repair work, check that the
working pressure, temperature and other characteristics are correctly set. Ensure that all
control devices are installed and functioning properly.
17. When replacing lters, separators etc., wipe away dust, dirt and oil residue from the
area where they are installed with a dry cloth.
18. Protect the motor, air lter, electrical components and control components etc. from
coming into contact with condensate. For instance, blow down with dry air.
19. Safety precautions for operation with refrigerants:
• Never inhale refrigerant vapours. Ensure that the work zone is properly ventilated; use a
respirator if necessary;
• Always wear special-purpose gloves. If the refrigerant comes into contact with skin, rinse
the area of contact with plenty of water. If refrigerant comes into contact with skin through
clothing, do not try to remove clothing. Thoroughly rinse clothing with fresh water until the
refrigerant is washed off. Then seek medical assistance.
20. Use protective gloves during installation and repair work in order to avoid burns and
injury (for instance, during oil change).
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COMPRAG RDX series compressed air refrigerated dryer
2. Technical data and functional description
Entitlement to free handling of faults arising during the guarantee pe-
riod is forfeited when:
- No warranty service coupon for the compressor or it is lled out
incorrectly
- No records for the compressor’s scheduled maintenance are entered
in the compressor’s service book
- Unoriginal parts and lubricants are used
2.1 Technical data
Model RDX04 RDX06 RDX09 RDX12 RDX18
Article 14310000 14310001 14310002 14310003 14310004
Capacity*, (m3/min) 0,4 0,6 0,9 1,2 1,8
Maximum working pressure, bar 16
Maximum inlet temperature of
compressed air, 0C+55
Maximum ambient temperature, оС +45
Pressure dew point, 0C +3
Type of refrigerant R134a
Quantity of refrigerant, kg 0,16 0,21 0,24 0,34 0,40
Thread connection G1/2“, internal thread
Power supply 1/230 V – 50 Hz
Power required, kW 0,13 0,16 0,18 0,27 0,29
Model RDX24 RDX30 RDX36 RDX41
Article 14310005 14310006 14310007 14310008
Capacity*, (m3/min) 2,4 3,0 3,6 4,1
Maximum working pressure, bar 14
Maximum inlet temperature of
compressed air, 0C+55
Maximum ambient temperature, оС +45
Pressure dew point, 0C +3
Type of refrigerant R404a
Quantity of refrigerant, kg 0,35 0,35 0,46 0,46
Thread connection G1“, internal thread
Power supply 1/230 V – 50 Hz
Power required, kW 0,47 0,61 0,74 0,83
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10 Version 1.4
Model RDX52 RDX65 RDX77
Article 14310009 14310010 14310011
Capacity*, (m3/min) 5,2 6,5 7,7
Maximum working pressure, bar 14
Maximum inlet temperature of
compressed air, 0C+55
Maximum ambient temperature, оС +45
Pressure dew point, 0C +3
Type of refrigerant R404a
Quantity of refrigerant, kg 0,52 0,65 0,77
Thread connection G1 1/2“, internal thread
Power supply 1/230 V – 50
Power required, kW 0,95 1,15 1,5
Model RDX100 RDX120 RDX150 RDX180
Article 14310012 14310013 14310014 14310015
Capacity*, (m3/min) 10,0 12,0 15,0 18,0
Maximum working pressure, bar 14
Maximum inlet temperature of
compressed air, 0C+55
Maximum ambient temperature, OС +45
Pressure dew point, 0C +3
Type of refrigerant R404a
Quantity of refrigerant, kg 1,00 1,10 1,50 1,80
Thread connection G2 1/2“, internal thread
Power supply 3/380 V – 50 Hz
Power required, kW 2,1 2,2 2,5 3,0
*In conformity with ISO 7183 under standard operating conditions:
working pressure 7 bar, ambient temperature +25°C, compressed air inlet temperature +35°C.
2.2 Function
RDX series compressed air refrigerating dryers are designed for removing condensate
from compressed air entering the compressed-air line from a compressor.
Air drying takes place by means of cooling the ow of compressed air to a temperature at
which water vapour, present in the compressed air, reaches saturation point (dew-point) and
turns from gaseous state to liquid. Condensate formed this way is extracted by the conden-
sate drain valve, which is actuated at set intervals on a time relay.
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COMPRAG RDX series compressed air refrigerated dryer
2.3 Functional description
2
1
9
6
5
8
7
34
AIR
REFRIGERANT
Fig. 2.1 Flow chart of compressed air dryer
1.Compressor
2.Evaporator
3.Condenser
4.Condenser fan
5.Refrigerant drying lter
6.Capillary tube
7.Hot gas bypass valve
8.Pressure relay of fan
9.Condensate drain valve
Compressor (1) injects hot refrigerant into condenser (3), where a large amount of the
refrigerant is turned into liquid form. The liquid refrigerant passes via the lter (5) into
the capillary tube (6). After passing through the capillary tube (6) and before entering the
evaporator (2), the pressure of the liquid refrigerant is lowered to boiling pressure with a
change from liquid to gaseous form. The refrigerant in the evaporator (2) receives the heat
from the compressed air by means of heat exchange and fully changes to a gaseous state.
The compressed air cools to dew-point +3°С by means of heat exchange. The water vapour
present in the compressed air is condensed. The condensate formed is extracted by the
condensate drain valve (9). Hot refrigerant enters the suction line of the compressor (1)
from the evaporator (2) and the cycle repeats itself. In order to stabilize the pressure of the
refrigerant in the condenser (3), a pressure relay (8) is installed, which controls function of
the fan (4). If the pressure in the evaporator (2) drops (insufcient quantity of compressed
air enters the dryer, no-load operation) a hot gas bypass valve is activated and it allows
pressure in the evaporator to drop lower than the dened level.
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12 Version 1.4
2.4 Conversion table of performance for different
operating conditions
RDX refrigerated dryers are designed in conformity with ISO 7183 under standard operat-
ing conditions: working pressure 7 bar, ambient temperature +25°C, compressed air inlet
temperature +35°C.
Any deviation from standard conditions requires dryer size adjustments.
Use Correction Factor tables to help determine dryer size.
Maximum working pres-
sure, MPa 00,1 0,2 0,4 0,6 0,7 0,8 1,0 1,2 1,4 1,6
F1 X X X 1,25 1,06 1,00 0,96 0,90 0,86 0,82 0,8
Maximum inlet temperature of compressed air, 0C +30 +35 +40 +45 +50 +55
F2 0,85 1,00 1,18 1,39 1,67 2,00
Ambient Temperature, °C +20 +25 +30 +35 +40 +45
F3 0,92 1,00 1,07 1,14 1,22 1,3
Capacity = Capacity at standard operating conditions x F1 x F2 x F3
3. Start-up
3.1 Acceptance of dryer
The dryer is packaged in a cardboard box.
If the equipment is delivered during the winter months, then the
equipment should be kept in a warm facility for no fewer than 12
hours before the packaging is removed after unloading.
This will prevent condensate from reaching the equipment’s inter-
nal components.
Upon delivery and unloading of the dryer, inspect the packaging for damage. Remove the
packaging, inspect the dryer for damage. Pay close attention to the control panel.
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COMPRAG RDX series compressed air refrigerated dryer
If above-mentioned defects are found, contact the supplier of your
dryer for explanation of further action.
3.2 Dimensions of dryer
D
H
L
Fig. 3.1 Dryer dimensions
Model
Dryer Dryer (packaged)
Height
H, mm
Width
D, mm
Length
L, mm
Mass,
kg
Height,
mm
Width,
mm
Length,
mm
Mass,
kg
RDX04
501 360 518
34
650 404 544
40
RDX06 35 41
RDX09 36 42
RDX12 36 42
RDX18 38 44
RDX24
808 508 554
47
969 670 560
53
RDX30 52 58
RDX36 60 66
RDX41 65 71
RDX52
890 512 562
72
1055 650 563
79
RDX65 75 82
RDX77 86 93
RDX100
1150 850 800
172
1373 926 926
177
RDX120 175 182
RDX150 180 185
RDX180 183 188
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14 Version 1.4
3.3 Preparation of facility
Remove the dryer from the pallet.
Ensure that the oor of the facility can withstand the weight of the dryer. Install the dryer
on a level surface that is able to bear its weight.
Regulate the horizontal axis of the dryer using a leveling instrument. The gradient from
the horizontal surface must not exceed 30. Install the dryer in a facility in which precipita-
tion cannot permeate. Choose a facility for installing the dryer with a minimum level of dust.
Install the dryer at least 1.5 m from a wall. A minimum 0.5 m should be allowed between
the rear side of the dryer and a wall. The facility in which the dryer is installed must be
good ventilated or tted with a combined extract-and-input ventilation system.
3.4 Preparation of compressed-air line
Connect the dryer to the compressed-air line. Provide the throughput capacity of the
compressed-air line in accordance with the capacity of the dryer.
All components of the compressed air line must have a working
pressure no less than the dryer’s nominal pressure.
3.5 Electrical connection
A1
S1
C
F
C
V1
A1
2A
K1
F1
K1.1
S1.2
H1.3
S1.1
A1
230V
230V
R
M2
1~
ba
c
M2
1~
ba
2
1
2
1
c
P
Fig.3.5.1 V.2 Electric schematic diagram RDX 04-77
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COMPRAG RDX series compressed air refrigerated dryer
K1 Contactor V1 Plug
K2 Contactor S3 Pressure switch HP failure
M1 Compressor S2 Pressure switch LP failure
M2 Fan TN1 Overload relay
A1 Condensate drain valve Q1 Main switch
S1 Fan pressure switch R Controller board
F1, F2 Fuse K5 Timing switch
Fig.3.5.2 V.2 Electric schematic diagram RDX 100-180
К1 Contactor M1 Compressor
S1.1
S1.2
H1.3
Start/Stop Button M2 Fan
F1 Fuse A1 Condensate drain valve
V1 Plug S1 Fan pressure switch
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4. Usage
4.1 Control panel
The control panel of the dryer comprises a main switch, start and stop buttons, dew-point
indicator and system state indicators.
www.comprag.com
RDX
134
2
Fig. 4.1.1 V.2 RDX 04-18 control panel
Pos. 1 Dryer ON Button
Pos. 2 Dryer OFF Button
Pos. 3 Dew-point indicator
Pos. 4 Dryer ON Indicator
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COMPRAG RDX series compressed air refrigerated dryer
Pos. 1 Dryer ON Button
Pos. 2 Dryer OFF Button
Pos. 3 Dew-point indicator
Pos. 4 Dryer ON Indicator
www.comprag.com
RDX
134
2
Fig. 4.1.2 V.2 RDX-24-77 control panel
13
429
56 78
Fig. 4.1.3 V.2 RDX-100-180 control panel
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18 Version 1.4
Pos. 1 Main switch
Pos. 2 Dew-point indicator
Pos. 3 Dryer ON button
Pos. 4 Dryer OFF button
Pos. 5 Dryer ON indicator green
Pos. 6 Compressor ON indicator yellow
Pos. 7 Low pressure failure
Pos. 8 High pressure failure
Pos. 9 Electric failure
Dew-point indicator
The dew-point indicator has 3 zones:
Green zone — optimum operating mode
Orange zone — system overcooled
Red zone — system overheated
REFRIGERANT PRESSURE RELAY S1-S2-S3
In order to ensure safe operation and integrity of the dryer, several pressure relays are
installed in the refrigerant gas circuit.
S1: The fan pressure relay is arranged on the discharge side of the compressor. It is used
to maintain constant temperature and condensate pressure within preset values (air cooling).
Pressure value: R 134.a Start-up at 12 bar (50,0°C) – Shutdown at 9 bar (40,0°C).
R 134.a Start-up at 23 bar (52,0°C) – Shutdown at 19 bar (44,0°C) – Deviation ±1 bar
S2: The low-pressure relay is arranged on the suction side (crankcase) of the compressor.
It is actuated if the pressure falls below the preset value. It is automatically reset when
the nominal pressure value is reached.
Pressure value: R 404 A Shutdown at 1.5 bar (-24,7°C) – Start-up at 5.5 bar (2,5°C).
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COMPRAG RDX series compressed air refrigerated dryer
1
2
Fig. 4.1.3 Reset of high-pressure relay
1. High-pressure relay
2. Manual release push button
S3: The high-pressure relay is arranged on the discharge side of the compressor and is
actuated if the pressure exceeds the preset value. Attention: After a “high pressure error”
occurs, the dryer blocks a restart attempt as this recurring error may cause damage to
the dryer. It is manually reset using the button on the actual pressure relay. In order to do
this, unscrew the left panel and press the discharge button, as shown in gure 4.1.3. The
cause of the error needs to be remedied before it can be unblocked.
Pressure value: R 404 A Shutdown at 30 bar (64,2°C) - Manual start-up at 24 bar (54,0°C).
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20 Version 1.4
4.2 Before use and on a weekly basis
Ensure the dryer’s power cable is intact.
Ensure that the compressed air hoses are connected to the compressed air inlet and outlet
of the dryer.
4.3 Turning on dryer
Do not permit unqualied personnel to use the dryer
1. Turn the main switch from position “0” to position “1”.
2. The indicator ‘Dryer ON’ lights up.
3. Press the Start button.
4.4 Turning off dryer
Do not turn off the dryer if the compressed air system is under
pressure.
The dryer is turned off by pressing the Dryer OFF button on the control panel and turning
the main switch from position “1” to position “0”.
After turning the main switch from position “1” to position “0”, the status indicator on the
control panel should go out.
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